Embossed paper-based bakeable tray

ABSTRACT

An embossed paper-based bakeable tray having a bottom surface and sidewalls and an embossed pattern formed in the bottom surface providing a series of closely spaced projections substantially entirely over the bottom surface.

This is a continuation-in-part of U.S. patent application Ser. No.13/273,029 filed Oct. 13, 2011.

BACKGROUND

Paper-based, oven-ready or bakeable trays are well known in the art forbaking, heating, or reheating foods. Such paper-based bakeable trays arecommonly used by “take-and-bake” pizza companies. Paper-based bakeabletrays are also used by makers of frozen pizza, partial baked “par-bake”and raw pizza dough. These paper-based bakeable trays include barriercoatings such that they are impermeable to liquids and can withstandtypical oven temperatures. While these trays may serve their intendedpurpose, it has been found that when foods are baked in theseconventional trays, the food may not cook uniformly. For example, whenpizza is cooked on these conventional trays, that the pizza crust in themiddle of the tray is often soft and doughy. Accordingly there is a needfor a paper-based bakeable tray that promotes uniform cooking.

Additionally, conventional paper-based bakeable trays have a flat orsubstantially flat bottom. When the cooked food is allowed to sit inthese flat bottom trays, the food often becomes soggy from condensationor from grease or other juices dripping from the food. Accordingly thereis a need for a paper-based bakeable tray that minimizes or prevents thefood baked within the tray from becoming soggy due to condensation orfrom sitting in its own juices while cooking or after cooking.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of one type of conventional paper-basedbakeable tray with a flat bottom surface.

FIG. 2 is a perspective view of another type of conventional paper-basedbakeable tray with raised contour surfaces in the form of a pinwheelpattern on the bottom surface of the tray.

FIG. 3 is a perspective view of yet another type of conventionalpaper-based bakeable with raised contour surfaces in the form of anoctagonal pattern on the bottom surface of the tray.

FIG. 4 is a plan view of one embodiment of a paper-based bakeable traysimilar to the conventional paper-based bakeable tray of FIG. 1, butwith an embossing pattern comprising upward projections on the bottomsurface of the tray.

FIG. 5 is a partial cross-sectional view of the embossed paper-basedbakeable tray of FIG. 4 as viewed along lines 5-5 of FIG. 4.

FIG. 6 is a plan view of one embodiment of a paper-based bakeable traysimilar to the conventional paper-based bakeable tray of FIG. 1, butwith an embossing pattern comprising upward projections and downwarddepressions on the bottom surface of the tray.

FIG. 7 is a partial cross-sectional view of the embossed paper-basedbakeable tray of FIG. 6 as viewed along lines 7-7 of FIG. 6.

FIG. 8 is a plan view of one embodiment of a paper-based bakeable traywith raised contour surfaces in the form of a pinwheel as in FIG. 2, butwith an embossing pattern on one side of the bottom of the tray.

FIG. 9 is a partial cross-sectional view of the embossed paper-basedbakeable tray of FIG. 8 as viewed along lines 9-9 of FIG. 8.

FIG. 10 is a partial cross-sectional view of the embossed paper-basedbakeable tray of FIG. 8 as viewed along lines 10-10 of FIG. 8.

FIG. 11 is a plan view of one embodiment of a paper-based bakeable traywith raised contour surfaces in the form of a pinwheel as in FIG. 2, butwith an embossing pattern comprising upward projections and downwarddepressions on the bottom surface of the tray.

FIG. 12 is a partial cross-sectional view of the embossed paper-basedbakeable tray of FIG. 11 as viewed along lines 12-12 of FIG. 11.

FIG. 13 is a partial cross-sectional view of the embossed paper-basedbakeable tray of FIG. 11 as viewed along lines 13-13 of FIG. 11.

FIG. 14 is a plan view of one embodiment of a paper-based bakeable traywith raised contour surfaces in the form of an octagonal pattern as inFIG. 3, but with an embossing pattern on one side of the bottom of thetray.

FIG. 15 is a partial cross-sectional view of the embossed paper-basedbakeable tray of FIG. 14 as viewed along lines 15-15 of FIG. 14.

FIG. 16 is a partial cross-sectional view of the embossed paper-basedbakeable tray of FIG. 14 as viewed along lines 16-16 of FIG. 14.

FIG. 17 is a plan view of one embodiment of a paper-based bakeable traywith raised contour surfaces in the form of an octagonal pattern as inFIG. 3, but with an embossing pattern comprising upward projections anddownward depressions on the bottom surface of the tray.

FIG. 18 is a partial cross-sectional view of the embossed paper-basedbakeable tray of FIG. 17 as viewed along lines 18-18 of FIG. 17.

FIG. 19 is a partial cross-sectional view of the embossed paper-basedbakeable tray of FIG. 17 as viewed along lines 19-19 of FIG. 17.

FIG. 20 is a plan view of one embodiment of a paper-based bakeable traywith raised contour surfaces in the form of a pinwheel as in FIG. 8, butwith an embossing pattern on one side of the bottom of the tray andlocated only between the contour surfaces.

FIG. 21 is a partial cross-sectional view of the embossed paper-basedbakeable tray of FIG. 20 as viewed along lines 21-21 of FIG. 20

FIG. 22 is a partial cross-sectional view of the embossed paper-basedbakeable tray of FIG. 20 as viewed along lines 22-22 of FIG. 20.

DESCRIPTION

Referring to the drawings, wherein like reference numerals designateidentical or corresponding parts throughout the several views, FIG. 1illustrates a conventional paper-based bakeable tray 10 having a bottomsurface 12 and sidewalls 14. The sidewalls may include a peripheral lip16. FIG. 2 illustrates a conventional paper-based bakeable tray 10having raised contour surfaces 20 formed in the bottom surface 12 in theform of a pinwheel pattern. FIG. 3 illustrates a conventionalpaper-based bakeable tray 10 having raised contour surfaces 20 formed inthe bottom surface 12 in the form of a an octagonal pattern. Theconventional paper-based trays 10 are typically formed using athermoforming process. As recognized and understood by those of skill inthe art, barrier coatings or barrier materials may be applied to thepaper-based material, before, during or after the thermoforming processor otherwise incorporated into the paper-based material such that thetrays are impermeable to liquids and/or to withstand typical oventemperatures.

FIG. 4 illustrates an embossed paper-based bakeable tray 100 similar tothe conventional paper-based bakeable tray 10 of FIG. 1. The embossedpaper-based bakeable tray 100 has a bottom surface 112 and sidewalls114. The sidewalls 114 may include a peripheral lip 116. However, unlikethe conventional tray 10, the embossed tray 100 includes an embossedpattern 102 formed in the bottom surface 112 of the tray. FIG. 5 is apartial cross-sectional view of the tray 100 as viewed along lines 5-5of FIG. 4. As used herein, the term “embossed pattern” should beunderstood to include any type of stamping, imprinting, pressing orforming process that creates a series of closely spaced intermittentprojections as opposed to raised contour surfaces 20 as depicted inFIGS. 2 and 3.

FIG. 6 illustrates a an alternative embodiment of an embossedpaper-based bakeable tray 200 similar to the conventional paper-basedtray 10 of FIG. 1, but with an embossed pattern 202 formed in the bottomsurface 212 of the tray and wherein the embossed pattern 202 comprisesboth upward and downward projections 204. The embossed paper-basedbakeable tray 200 has sidewalls 214 which may include a peripheral lip216. FIG. 7 is a partial cross-sectional view of the embossed tray 200as viewed along lines 7-7 of FIG. 6 showing the embossing pattern 202comprising both the upward and downward projections 204.

FIG. 8 illustrates a an alternative embodiment of an embossedpaper-based bakeable tray 300 similar to the conventional paper-basedtray 10 of FIG. 2 having raised contour surfaces 20 in the form of apinwheel, but with an embossed pattern 302 formed in the bottom surface312 of the tray and wherein the embossed pattern 302 comprises upwardprojections 304. The embossed paper-based bakeable tray 300 hassidewalls 314 which may include a peripheral lip 316. FIG. 9 is apartial cross-sectional view of the embossed tray 300 as viewed alonglines 9-9 of FIG. 8. FIG. 10 is a partial cross-sectional view of theembossed tray 300 as viewed along lines 10-10 of FIG. 8 illustrating thecross-sectional view of one of the raised contour surfaces 20 of thepinwheel pattern. As illustrated, the raised contour surfaces 20 of thepinwheel pattern include the embossed pattern 302, but it should beappreciated that, if desired, the embossed pattern 302 may only beprovided between the raised contour surfaces 20. An embodiment of thisconfiguration with the embossed pattern 302 existing only between theraised contour surfaces 20 is illustrated in FIG. 20. Similarly, across-sectional view is illustrated in FIG. 21, as viewed along lines21-21 of FIG. 20.

FIG. 11 illustrates a an alternative embodiment of an embossedpaper-based bakeable tray 400 similar to the conventional paper-basedtray 10 of FIG. 2 having raised contour surfaces 20 in the form of apinwheel, but with an embossed pattern 402 formed in the bottom surface412 of the tray and wherein the embossed pattern 402 comprises bothupward and downward projections 404. The embossed paper-based bakeabletray 400 has sidewalls 414 which may include a peripheral lip 416. FIG.12 is a partial cross-sectional view of the embossed tray 400 as viewedalong lines 12-12 of FIG. 11. FIG. 13 is a partial cross-sectional viewof the embossed tray 400 as viewed along lines 13-13 of FIG. 11illustrating the cross-sectional view of one of the raised contoursurfaces 20 of the pinwheel pattern. As illustrated, the raised contoursurfaces 20 of the pinwheel pattern include the embossed pattern 402,but it should be appreciated that, if desired, the embossed pattern 402may only be provided between the raised contour surfaces 20.

FIG. 14 illustrates a an alternative embodiment of an embossedpaper-based bakeable tray 500 similar to the conventional paper-basedtray 10 of FIG. 3 having raised contour surfaces 20 in the form of anoctagonal pattern, but with an embossed pattern 502 formed in the bottomsurface 512 of the tray and wherein the embossed pattern 502 comprisesupward projections 504. The embossed paper-based bakeable tray 500 hassidewalls 514 which may include a peripheral lip 516. FIG. 15 is apartial cross-sectional view of the embossed tray 500 as viewed alonglines 15-15 of FIG. 14. FIG. 16 is a partial cross-sectional view of theembossed tray 500 as viewed along lines 16-16 of FIG. 14 illustratingthe cross-sectional view of one of the raised contour surfaces 20 of theoctagonal pattern. As illustrated, the raised contour surface 20 of theoctagonal pattern includes the embossed pattern 502, but it should beappreciated that, if desired, the embossed pattern 502 may only beprovided between the raised contour surfaces 20.

FIG. 17 illustrates a an alternative embodiment of an embossedpaper-based bakeable tray 600 similar to the conventional paper-basedtray 10 of FIG. 3 having raised contour surfaces 20 in the form of anoctagonal pattern, but with an embossed pattern 602 formed in the bottomsurface 612 of the tray and wherein the embossing pattern 602 comprisesboth upward and downward projections 604. The embossed paper-basedbakeable tray 600 has sidewalls 614 which may include a peripheral lip616. FIG. 18 is a partial cross-sectional view of the embossed tray 600as viewed along lines 18-18 of FIG. 17. FIG. 19 is a partialcross-sectional view of the embossed tray 600 as viewed along lines19-19 of FIG. 17 illustrating the cross-sectional view of one of theraised contour surfaces 20 of the octagonal pattern. As illustrated, theraised contour surface 20 of the octagonal pattern includes the embossedpattern 602, but it should be appreciated that, if desired, the embossedpattern 602 may only be provided between the raised contour surfaces 20.

Each of the embossed paper-based bakeable trays 100, 200, 300, 400, 500,600 may be formed in the same manner using the same type ofthermoforming press used to produce conventional paperboard trays 10 butwith the desired embossing pattern formed in the face of the male and/orfemale dies used in the thermoforming press. The embossed trays may beused for a number of purposes and may take any desired shape. Forexample, rather than being a circular tray as shown, the tray may berectangular or triangular or it may take the shape of the food product.

The embossing patterns 102, 202, 302, 402, 502, 602 comprises a seriesof closely spaced projections 104, 204, 304, 404, 504, 604 formed intothe bottom surface 112, 212, 312, 412, 512, 612 of the paper-basedembossed trays 100, 200, 300, 400, 500, 600. The projections may be anysuitable configuration, size and spacing. As an example, the projectionsmay have a diameter of about 3/16 inch, and a height range between about0.010 to about 0.040 inches, with a center-to-center spacing of about ½inch. It should be appreciated, however, that the projections need notbe round or circular and may have any desired size or shape, includingany polygonal shape with widths and lengths or diameters between about ⅛inch to about 1 inch, and may be spaced at distances ranging from about⅜ inch to about 2 inches depending on the size of the projections.

The projections 104, 204, 304, 404, 504, 604 serve to intermittentlysupport the food product thereby allowing air circulation below the foodproduct so the food does not become soggy due to the collection ofcondensation, drippings or juices from the food as it is being cooked orafter cooking. The projections also provide an air space which minimizesheat transfer via conduction thereby keeping the food warmer for alonger period of time. With the embossed trays having both upward anddownward projections, the downward projections or depressions may permitadditional air circulation and serve as small wells in whichcondensation, food juices or drippings are collected.

It has been found that paper-based bakeable trays having an embossingpatterns as described herein improves the quality of certain foods whenreheating or baking, due to the projections creating an air space andallowing more air circulation below the food. For example it has beenfound that if a conventional flat (non-embossed) paper-based bakeabletray having a flat bottom surface as in FIG. 1 is formed with anembossing pattern as described herein, and if this embossed trays arethen used to bake pizza, the resulting crust is more uniformly cooked,is crispier and has a more uniform golden-brown crust. It was also foundthat if a black colored, conventional flat (non-embossed) paper basedbakeable tray such as illustrated in FIG. 1 is formed with an embossingpattern as described herein so as to create a black embossed paperboardtray, the resulting crust is even crispier and more golden-brown.

The embossed trays 100, 200, 300, 400, 500, 600 may be made of premiumgrade solid bleached sulfate (SBS) or any other suitable type of paper,paperboard, cardstock or cardboard material or any other type ofpulp-based, fiber-based or cellulose-based material, whether from wood,other plant or natural material or from synthetic material.

Depending on the application and intended use of the embossed trays 100,200, 300, 400, 500, 600 and the type of food it is intended to contact,the embossed trays may include appropriate barrier coatings as wellknown to those of skill in the art such that the embossed trays aresuitable for baking, heating, or reheating foods. Additionally, or inthe alternative, the embossed trays may include barrier coatings suchthat the embossed trays are freezer-to-oven ready and/or impermeable toliquids.

The foregoing description is presented to enable one of ordinary skillin the art to make and use the invention and is provided in the contextof a patent application and its requirements. Various modifications tothe embodiments of the apparatus and the general principles and featuresdescribed herein will be readily apparent to those of skill in the art.Thus, the present invention is not to be limited to the embodimentsdescribed above and illustrated in the drawing figures, but is to beaccorded the widest scope consistent with the spirit and scope of theappended claims.

The invention claimed is:
 1. An embossed paper-based bakeable tray forbaking a food product, comprising: a thermoformed paper-based bakeabletray having a bottom area and sidewalls extending upwardly from saidbottom area, wherein said bottom area is situated in a plane extendingfrom and connected to a bottom edge of the sidewalls; an embossedpattern formed in said bottom area, said bottom area having an uppersurface and a lower surface, said embossed pattern comprising aplurality of upper projections extending generally upwardly from saidupper surface and said embossed pattern comprising a plurality of lowerprojections extending generally downwardly from said lower surface, eachof said plurality of upper projections being circular and extendingabout 0.01 to about 0.04 inches above said upper surface of said bottomarea and having a planar upper projection surface, wherein said upperprojection surfaces form an intermittent upper support surface, and eachof said plurality of lower projections being circular and extendingabout 0.01 inches to about 0.04 inches below said lower surface of thebottom area and having a planar lower projection surface, wherein saidlower projection surfaces form an intermittent lower support surface,and wherein each lower projection forms a reservoir configured tocollect liquid, and wherein said intermittent upper support surface isadapted to support a food product placed thereon while also providing anopen space under the food product, and wherein said intermittent lowersupport surface provides an open space that allows for air circulationbelow said lower surface and a support surface on which said tray isplaced.
 2. The embossed paper-based bakeable tray of claim 1 whereinsaid bottom area of said tray includes raised contour surfaces andwherein said embossed pattern is formed in said raised contour surfacesand between said raised contour surfaces.
 3. The embossed paper-basedbakeable tray of claim 1 wherein said bottom area of said tray includesraised contour surfaces and wherein said embossed pattern is formed onlybetween said raised contour surfaces.
 4. The embossed paper-basedbakeable tray of claim 2 wherein said raised contour surfaces are in theshape of a pinwheel pattern.
 5. The embossed paper-based bakeable trayof claim 2 wherein said raised contour surfaces are in the shape of anoctagonal pattern.
 6. The embossed paper-based bakeable tray of claim 3wherein said raised contour surfaces are in the shape of a pinwheelpattern.
 7. The embossed paper-based bakeable tray of claim 3 whereinsaid raised contour surfaces are in the shape of an octagonal pattern.8. The embossed paper-based bakeable tray of claim 1 wherein saidthermoformed paper-based bakeable tray has a thermal conductivitybetween about 0.01 W·m⁻¹·K⁻¹ to about 2.0 W·m⁻¹·K⁻¹.
 9. The embossedpaper-based bakeable tray of claim 8 wherein said baking occurs at atemperature between about 150 degrees Fahrenheit and about 500 degreesFahrenheit.